Resistance Soldering Power-Time Control for Consistent Joints
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Solution Overview
Problem
Existing resistance soldering systems lack control over the desired time of power delivery to a solder joint, which can result in inconsistent soldering quality due to varying electrical connections.
Innovation Solution
A resistance soldering system that includes a controller circuit to independently control both the desired power level and time, using a silicon-controlled rectifier and transformer to deliver a controlled voltage and current to the solder joint, allowing for user-defined soldering profiles based on joint characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing resistance soldering systems are used, then soldering can be performed, but control over power delivery time is lacking resulting in inconsistent soldering quality
Solution Approach 1:
The system dynamically adjusts both power level and time duration independently through a controller circuit that regulates a silicon-controlled rectifier. This allows the soldering process to adapt to varying joint characteristics while maintaining consistent quality, resolving the contradiction between manufacturing precision and device complexity by implementing controlled dynamic parameters.
Solution Approach 2:
The invention changes two key parameters independently: power level (via controller regulation of the silicon-controlled rectifier) and time duration (via programmable control logic). This dual-parameter control enables precise soldering quality consistency without excessive system complexity, as each parameter can be optimized separately based on joint requirements.
2Reliability
If power delivery time is not controlled, then system operation is simple, but soldering quality varies due to electrical connection differences
Solution Approach 1:
The controller circuit automatically manages power delivery time and level based on pre-programmed parameters, eliminating the need for manual timing control. The system serves itself by internally regulating the silicon-controlled rectifier for the precise duration required, thereby improving reliability without significantly complicating operation for the user.
Solution Approach 2:
The system incorporates feedback through its controller circuit that monitors and adjusts power delivery based on electrical connection conditions. This feedback mechanism ensures consistent soldering quality by automatically compensating for variations in electrical connections, maintaining reliability while keeping operation simple through automated control.
3Manufacturing precision
If independent power level and time control is implemented, then soldering precision is improved, but additional control components are required
Solution Approach 1:
The controller circuit performs multiple functions: it regulates power level, controls time duration, and manages the silicon-controlled rectifier. By consolidating these control functions into a single multi-functional controller, the system achieves high power delivery precision without proportionally increasing overall device complexity, as one component handles multiple control tasks.
Solution Approach 2:
The invention merges the power level control and time control functions into a unified controller circuit that simultaneously manages both parameters. This consolidation achieves precise independent control of power and time while reducing the total number of separate control components, thereby improving manufacturing precision without excessive complexity increase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system improves soldering consistency by allowing precise control over power delivery, enabling the melting of solder joints with defined power levels and times, independent of the quality of the electrical connection, thus enhancing the resistance soldering process with an additional degree of freedom.
Implementation Method 1
resistance soldering system
Implementation Method 2
controls a power delivered to a solder joint for a specified time to melt the solder joint
Data Source
AI summary
A resistance soldering system includes a power input receiving an alternating current from a power source and a controller circuit generating a control signal indicative of a desired power level delivered for a desired time. The resistance soldering system further includes a silicon-controlled rectifier connected to the power input and the controller circuit and producing a control voltage proportional to the control signal and a transformer having a primary side receiving the control voltage and a secondary side having output leads configured to apply an output voltage to a solder joint disposed between the output leads. The controller circuit determines the control signal applied to the silicon-controlled rectifier required to melt the solder joint based on the desired power level and the desired time. The controller circuit controls the desired power level independent of the desired time. A method of operating a resistance soldering system is also presented.